Course Instructor – Dr. Swati Singh

Lean Manufacturing

Presentation by Ashutosh Trivedi

Asma Tahir

Avinash Narang

Astha Saxena

LEAN MANUFACTURINGLean manufacturing focuses on reducing waste.

The concept of Lean Manufacturing was developed by Henry Ford in 1920’s

.Toyota was the first company to introduce ‘lean

manufacturing’ concept in its production system.

TYPES OF WASTEOVERPRODUCTIONINVENTORYMOTIONWAITINGTRANSPORTATIONRE-WORKOVER-PROCESSING

Principles of Lean Manufacturing• To create continuous flow . • To use pull-systems to manage the workflow • To reduce batch sizes and inventories • To eliminate waste • To cross-train workers in order to deal with

inherent variability • Selective use of automation • To instill a Continuous Improvement

competence

STEPS TO ACHIEVE LEAN SYSTEMS

Design a simple manufacturing system

Recognize that there is always room for improvement

Continuously improve the lean manufacturing system design

DESIGN A SIMPLE MANUFACTURING SYSTEM

A fundamental principle of lean manufacturing is demand-based flow manufacturing. In this type of production setting, inventory is only pulled through each production center when it is needed to meet a customer’s order.

1)decreased cycle time

2)increased productivity

3)less inventory

4)increased capital equipment utilization

THERE IS ALWAYS ROOM FOR IMPROVEMENT

The core of lean is founded on the concept of continuous product and process improvement and the elimination of non-value added activities.

Lean Manufacturing Methods • creative and innovative approaches to analysis and design

through the implementation of lean manufacturing methods.

Lean Manufacturing Waste

• These small stockpiles are known as kanban, and the use of the kanban significantly lowers waste and enhances productivity on the factory floor. In addition to eliminating waste, lean manufacturing seeks to provide optimum quality by building in a method whereby each part is examined immediately after manufacture, and if there is a defect, the production line stops so that the problem can be detected at the earliest possible time.

Lean Manufacturing System

• In a lean manufacturing system, suppliers deliver small lots on a daily basis, and machines are not necessarily run at full capacity.

• creative and innovative approaches to analysis and design through the implementation of lean manufacturing methods

Lean Production Manufacturing

Tools and materials are arranged and put in their proper location following the sequence of production. Manufacturing

Lean Manufacturing Quality

In addition to eliminating waste, lean manufacturing seeks to provide optimum quality by a method whereby each part is examined immediately after manufacture.

Lean Manufacturing Inventory

• Lean manufacturing centers around placing small stockpiles of inventory in strategic locations around the assembly line, instead of in centralized warehouses.

• The concept of lean is to simply eliminate waste

BENEFITS OF LEAN MANUFACTURING

• Productivity Improvement• Total manufacturing time saved• Less scrap• Low inventory• Quality improvement • Plant space saved• Better labor utilization• Safety of operations

Implementation Stages of Lean Manufacturing

Three stages in the implementation of ‘Lean Manufacturing’---

Data collection stageData analysis and development of solution Stage Implementation Stage  

TOYOTA LEAN MANUFACTURING SYSTEM

HISTORY

Kiichiro Toyoda, son of Sakichi and founder of the Toyota automobile business, developed the concept of Just-in-Time in the 1930s. He decreed that Toyota operations would contain no excess inventory and that Toyota would strive to work in partnership with suppliers to level production.

Taiichi Ohno, Toyota's chief of production in the post-WWII period. He was THE main developer of Toyota Production System (TPS).

Dr. Shigeo Shingo: A consultant to Toyota.

TOYOTA PRODUCTION SYSTEM (TPS)

Definition: The production system developed by Toyota Motor Corporation to provide best quality, lowest cost, and shortest lead time through the elimination of waste.

TPS is comprised of two pillars, Just-in-Time and Jidoka (autonomation).

TPS is maintained and improved through iterations of standardized work and kaizen (continuous improvement), following Plan–Do-Check-Act (PDCA Cycle from Dr. Deming), or the scientific method.

THE FIVE STEPS OF TOYOTA PRODUCTION SYSTEM IMPLEMENTATION

Step 1: Specify ValueDefine value from the perspective of the final customer. Express value in terms of a specific product, which meets the customer's needs at a specific price and at a specific time.

Step 2: Value Stream Mapping.Identify the value stream, the set of all specific actions required to bring a specific product through the three critical management tasks of any business: the problem-solving task, the information management task, and the physical transformation task. Create a map of the Current State and the Future State of the value stream. Identify and categorize waste in the Current State, and eliminate it!

Step 3: Create Continuous FlowMake the remaining steps in the value stream flow. Eliminate functional barriers and develop a product-focused organization that dramatically improves lead-time.

Step 4: Create Pull ProductionLet the customer pull products as needed.

Step 5: PerfectionThere is no end to the process of reducing effort, time, space, cost, and mistakes. Return to the first step and begin the next lean transformation, offering a product which is ever more nearly what the customer wants.

TOYOTA’S PHILOSOPHYSelling price – Cost = Profit Customers decide the selling price.Profit is what remains after subtracting the cost from it.The main way to increase profit is to reduce cost.Consequently, cost reduction through waste elimination

should have the highest priority.Toyota’s paradox: Reducing cost (waste), will reduce lead

time while increasing quality and customer satisfaction.

Flow with JIT

Traditional Flow

CustomersSuppliers

Customers

Suppliers

Production Process (stream of water)

Inventory (stagnant ponds)

Material(water in stream)

Thank You